Fiber optic connectors and methods of making the same

Abstract

Fiber optic connectors (10), cable assemblies (100) and methods for making the same are disclosed. In one embodiment, the fiber optic connector (10) comprises a ferrule assembly (52), a housing (20) and a cap (60). The housing (20) comprises a longitudinal passageway (22) between a rear end (21) and a front end (23), and a ferrule assembly side-loading pocket (40) for receiving the ferrule assembly (52). The ferrule assembly (52) and housing (20) cooperate to inhibit movement of the assembly during manufacturing. Fiber optic connector 10 may include other features as desired such as keying portion (20KP) or at least one locking feature (20L) integrally formed in the housing (20).

We claim: 
     
       1. A fiber optic connector, comprising:
 a ferrule assembly comprising a ferrule comprising at least one fiber bore, a ferrule holder and a resilient member, wherein the ferrule holder comprises two alignment features disposed on a first side of ferrule holder, and a third alignment feature configured as an alignment protrusion disposed on a second side that is opposite the first side of ferrule holder; 
 a housing comprising a rear end and a front end with a longitudinal passageway extending from the rear end to the front end, the housing comprising a front portion and a rear portion, wherein the front portion comprises a ferrule assembly side-loading pocket; and 
 a cap, wherein the cap covers the ferrule assembly side-loading pocket when attached to the housing. 
 
     
     
       2. The fiber optic connector of  claim 1 , wherein the two alignment features comprises one or more tapered surfaces. 
     
     
       3. A fiber optic connector, comprising:
 a ferrule assembly comprising a ferrule comprising at least one fiber bore, a ferrule holder and a resilient member, wherein the ferrule holder comprises two alignment features disposed on a first side of ferrule holder, and a third alignment feature configured as an alignment protrusion disposed on a second side that is opposite the first side of ferrule holder; 
 a housing comprising a rear end and a front end with a longitudinal passageway extending from the rear end to the front end, the housing comprising a front portion and a rear portion, wherein the front portion comprises a ferrule assembly side-loading pocket; and 
 a cap, wherein the cap comprises at least one latch arm, and the cap covers the ferrule assembly side-loading pocket when attached to the housing. 
 
     
     
       4. The fiber optic connector of  claim 3 , wherein the third alignment feature is disposed in the middle of the second side of ferrule holder and is different than the alignment features disposed on the first side. 
     
     
       5. A fiber optic connector, comprising:
 a ferrule assembly comprising a ferrule comprising at least one fiber bore, a ferrule holder and a resilient member, wherein the ferrule holder comprises two alignment features disposed on a first side of ferrule holder, and a third alignment feature configured as an alignment protrusion disposed on a second side that is opposite the first side of ferrule holder; 
 a housing comprising a rear end and a front end with a longitudinal passageway extending from the rear end to the front end, the housing comprising a front portion and a rear portion, wherein the front portion comprises a ferrule assembly side-loading pocket; and 
 a cap, wherein the cap covers the ferrule assembly side-loading pocket when attached to the housing. 
 
     
     
       6. The fiber optic connector of  claim 5 , wherein the housing further comprises a transition region disposed between the front portion and the rear portion of the housing. 
     
     
       7. The fiber optic connector of  claim 5 , wherein housing further comprises a keying portion comprising a female key. 
     
     
       8. The fiber optic connector of  claim 7 , wherein the keying portion extends into the transition region. 
     
     
       9. The fiber optic connector of  claim 5 , wherein housing further comprises at least one locking feature. 
     
     
       10. The fiber optic connector of  claim 5 , wherein housing further comprises at least one locking feature, and a keying portion comprising a female key. 
     
     
       11. The fiber optic connector of  claim 10 , wherein the at least one locking feature is disposed about 180 degrees from the keying portion. 
     
     
       12. The fiber optic connector of  claim 10 , wherein the at least one locking feature is disposed less than 180 degrees from the keying portion. 
     
     
       13. The fiber optic connector of  claim 5 , wherein the rear portion of the housing further comprises a keying portion and at least one locking feature integrally formed in the rear portion of the housing. 
     
     
       14. A fiber optic connector, comprising:
 a ferrule assembly comprising a ferrule comprising at least one fiber bore, a ferrule holder and a resilient member, wherein the ferrule holder comprises asymmetric alignment features comprising two alignment features disposed on a first side of ferrule holder, and a third alignment feature configured as an alignment protrusion disposed on a second side that is opposite the first side of ferrule holder; 
 a housing comprising a rear end and a front end with a longitudinal passageway extending from the rear end to the front end, the housing comprising a front portion, a rear portion and a transition region disposed between the front portion and the rear portion of the housing, wherein the front portion comprises a ferrule assembly side-loading pocket, and the rear portion of the housing comprises a keying portion that extends into a portion of the transition region, and at least one locking feature integrally formed in the rear portion of the housing, and the at least one locking feature is disposed about 180 degrees from the keying portion; and 
 a cap, wherein the cap covers the ferrule assembly side-loading pocket when attached to the housing. 
 
     
     
       15. A fiber optic connector, comprising:
 a ferrule assembly comprising a ferrule comprising at least one fiber bore, a ferrule holder and a resilient member, wherein the ferrule holder comprises asymmetric alignment features, wherein the asymmetric alignment features comprise two alignment features having respective tapered surfaces disposed on a first side of ferrule holder, and a third alignment feature configured as an alignment protrusion disposed on a second side that is opposite the first side of ferrule holder; 
 a housing comprising a rear end and a front end with a longitudinal passageway extending from the rear end to the front end, the housing comprising a front portion, a rear portion and transition region disposed between the front portion and the rear portion of the housing, the front portion of the housing comprising a ferrule assembly side-loading pocket, and wherein the rear portion of the housing comprises a female key that extends into a portion of the transition region, and at least one locking feature integrally formed in the rear portion of the housing, and wherein the at least one locking feature is disposed about 180 degrees from the female key; and 
 a cap, wherein the cap covers the ferrule assembly side-loading pocket when attached to the housing. 
 
     
     
       16. The fiber optic connector of  claim 15 , wherein the third alignment feature is disposed in the middle of the second side of ferrule holder and is different than the alignment features disposed on the first side. 
     
     
       17. The fiber optic connector of  claim 15 , wherein the ferrule assembly is configured to cooperate with the housing for inhibiting the rotation of the ferrule subassembly with respect to the housing at Z=0. 
     
     
       18. The fiber optic connector of  claim 15 , wherein housing comprises an open passageway to the longitudinal passageway of the housing. 
     
     
       19. The fiber optic connector of  claim 15 , wherein the housing comprises one or more apertures. 
     
     
       20. The fiber optic connector of  claim 15 , wherein the at least one locking feature is a ramp comprising a ledge. 
     
     
       21. The fiber optic connector of  claim 15 , wherein the at least one locking feature is a notch, a groove, a shoulder or a scallop. 
     
     
       22. The fiber optic connector of  claim 20 , wherein the at least one locking feature provides a predetermined retention force of 50 pounds or more. 
     
     
       23. The fiber optic connector of  claim 15 , wherein a part of the rear portion of the housing comprises a round cross-section and a part of the front portion of the housing comprises a non-round cross-section. 
     
     
       24. The fiber optic connector of  claim 15 , further comprising a male key. 
     
     
       25. The fiber optic connector of  claim 15 , wherein the front portion of housing comprises another cross-section portion. 
     
     
       26. The fiber optic connector of  claim 25 , wherein the another cross-section portion comprises a SC footprint or a SC compatible footprint. 
     
     
       27. The fiber optic connector of  claim 15 , further comprising a cable adapter. 
     
     
       28. The fiber optic connector of  claim 27 , wherein an opening at the rear end of the housing is sized for receiving a portion of a cable assembly. 
     
     
       29. The fiber optic connector of  claim 15 , further comprising an O-ring. 
     
     
       30. The fiber optic connector of  claim 29 , wherein the O-ring is disposed rearward of the at least one locking feature. 
     
     
       31. The fiber optic connector of  claim 15 , further comprising a dust cap. 
     
     
       32. The fiber optic connector of  claim 15 , further comprising a conversion housing, wherein the conversion housing cooperates with the housing for changing the fiber optic connector from the first connector footprint to a second connector footprint. 
     
     
       33. The fiber optic connector of  claim 32 , wherein the second footprint comprises a hardened connector footprint. 
     
     
       34. The fiber optic connector of  claim 32 , wherein the changing from the first connector footprint to the second connector footprint comprises a single component. 
     
     
       35. The fiber optic connector of  claim 32 , wherein the changing from the first connector footprint to the second connector footprint comprises a plurality of components. 
     
     
       36. The fiber optic connector of  claim 32 , wherein the second connector footprint is a SC connector footprint or a SC compatible connector footprint. 
     
     
       37. The fiber optic connector of  claim 32 , wherein the changing from the first connector footprint to the second connector footprint comprises a shroud, a retaining member, and a coupling nut. 
     
     
       38. The fiber optic connector of  claim 32 , the second connector footprint is an OptiTap® compatible footprint. 
     
     
       39. The fiber optic connector of  claim 27 , wherein the retaining member is a retaining clip. 
     
     
       40. The fiber optic connector of  claim 15  being a portion of a cable assembly. 
     
     
       41. The fiber optic connector of  claim 15  being a portion of a distribution cable. 
     
     
       42. The fiber optic connector of  claim 15 , further comprising a fiber optic cable comprising at least one strength element, the at least one strength element of the fiber optic cable being attached to a portion of the fiber optic connector. 
     
     
       43. A fiber optic cable assembly, comprising:
 a ferrule assembly comprising a ferrule comprising at least one fiber bore, a ferrule holder and a resilient member, wherein the ferrule holder comprises asymmetric alignment features, wherein the asymmetric alignment features comprise two alignment features having respective tapered surfaces disposed on a first side of ferrule holder, and a third alignment feature configured as an alignment protrusion disposed on a second side that is opposite the first side of ferrule holder; 
 a housing comprising a rear end and a front end with a longitudinal passageway extending from the rear end to the front end, the housing comprising a front portion, a rear portion and transition region disposed between the front portion and the rear portion of the housing, wherein the front portion of the housing comprising a ferrule assembly side-loading pocket, and wherein the rear portion of the housing comprises a female key that extends into a portion of the transition region, and at least one locking feature integrally formed in the rear portion of the housing, and the at least one locking feature is disposed about 180 degrees from the female key; 
 a cap covers the ferrule assembly side-loading pocket when attached to the housing; 
 a cable adapter sized for fitting into the rear opening of the housing; and 
 a cable comprising an optical fiber, and the cable being attached to the cable adapter.